Functional sheet manufactured through a powder spray method and method of manufacturing the same

Abstract

A method of manufacturing a functional sheet according to an embodiment of the present invention, comprise powdering a filler with specific functional component and a binder, charging the filler and the binder with second polarity, spraying the binder and the filler onto an upper surface of an electrode plate charged with first polarity opposite to the second polarity, heat-treating the binder and filler, pressing an upper surface of the filler with a rolling roller, and separating the binder and the filler from the electrode plate. Therefore, the method can improve functionality while reducing harmfulness by manufacturing the functional sheet using a powdered filler and binder without using an organic solvent.

What is claimed is: 
     
       1. A method of manufacturing a functional sheet, comprising:
 disposing a base film moving on an electrode plate that is charged with positive polarity in a roll-to-roll device; 
 powdering a filler having functional components; 
 bonding via a binder configured to bond between the functional components; 
 charging the filler and the binder with negative polarity; 
 spraying the filler and the binder onto an upper surface of the base film; 
 heat-treating the base film onto which the filler and the binder are sprayed corresponding to a melting temperature of the binder to melt the binder; and 
 supplying heat to a lower surface of the base film, and pressing the upper surface of the base film with a rolling roller, 
 wherein spraying the filler and the binder onto an upper surface of the base film, comprises: 
 spraying the filler onto the upper surface of the base film; 
 spraying a powder in which the filler and the binder are mixed onto the upper surface of the filler; and 
 spraying the filler onto the upper surface of the powder in which the filler and the binder are mixed. 
 
     
     
       2. The method of  claim 1 , further comprising:
 attaching a protection film to the lower surface of the base film to manufacture a functional sheet. 
 
     
     
       3. The method of  claim 1 , wherein the filler comprises at least one of boron nitride, graphite, alumina, sandust, fullerene, and carbon nanotube (CNT). 
     
     
       4. The method of  claim 1 , wherein the binder comprises at least one of a thermoplastic resin, a polymer compound, epoxy, paraffin, urethane, and silicone. 
     
     
       5. A method of manufacturing a functional sheet, comprising:
 powdering a filler with a functional component; 
 bonding via a binder configured to bond between the functional component; 
 charging the filler and the binder with negative polarity; 
 spraying the binder and the filler onto an upper surface of an electrode plate charged with positive polarity; 
 heat-treating the binder and filler corresponding to a melting temperature of the binder to melt the binder; 
 pressing an upper surface of the filler with a rolling roller; and 
 separating the binder and the filler from the electrode plate to manufacture a functional sheet, 
 wherein spraying the binder and the filler onto an upper surface of an electrode plate charged with first polarity opposite to the second polarity, comprises: 
 spraying the binder over the entire upper surface of the electrode plate; and 
 spraying different types of fillers for a region of the upper surface of the binder, 
 or, spraying different types of binders for a region of the upper surface of the electrode plate; and 
 spraying different types of fillers for an area of an upper surface of the binder, 
 or, spraying different types of binders for the region of the upper surface of the electrode plate; and 
 spraying one type of filler over the entire area of an upper surface of the binder. 
 
     
     
       6. The method of  claim 5 , wherein powdering a filler with a functional component and a binder, comprises:
 powdering the filler and the binder such that a particle size of the filler is larger than a particle size of the binder.